Kitchen range hood

ABSTRACT

A kitchen range hood having an improved connection as between the range hood body and the exhaust chamber housing. The range hood body has a top panel and defines an enclosure in which the exhaust chamber housing is mounted. The housing has a peripheral wall terminating in a flange at one end and a bottom surface at the other. The flange is connected to the top panel. A pocket between the flange and the top panel is filled with a seal.

FIELD OF THE INVENTION

This invention relates to kitchen range hoods. In particular, this invention relates to the mounting of an exhaust chamber housing within a range hood body and the connection between the two.

BACKGROUND OF THE INVENTION

Kitchen range hoods are used for venting gases from above a cooking surface. The body of a kitchen range hood typically comprises a top panel, two side panels, a rear panel and a bottom panel to accommodate one or more air intakes and fan grills. The panels are generally joined at their edges by welding and form an enclosure.

An exhaust chamber housing is mounted within the hood body. At least one motor and one fan are mounted within the exhaust chamber for venting gases drawn in through the air intake(s) and expelled through an exhaust vent to an exterior location. During the process of venting grease-laden air, grease accumulates on the inside of the exhaust chamber.

At its most basic, the exhaust chamber is defined by the top panel of the range hood body and the sides and bottom of the exhaust chamber housing. This exhaust chamber configuration for range hoods is taught in U.S. Pat. Nos. 5,228,428 and 5,537,988.

For ease of reference, this type of prior art design is shown in FIG. 1. Range hood 100 has a top panel 44 and an exhaust chamber housing 46 connected thereto forming an exhaust chamber 45 within which motor 8 and fan 10 are mounted. The exhaust chamber housing 46 has a peripheral wall 47 terminating in a flange 48 at the top and terminating in a bottom surface 49 at the bottom, the bottom surface having at least one intake opening defined therein. The intake opening in the exhaust chamber housing is aligned with the air intake defined in a bottom panel 14 of the range hood. A grease tray 42 is releasably connectable to the bottom surface 49 to capture any grease that may drain into it from the exhaust housing interior or that may drip from the fan 10 after the motor 8 has been shut off and to help direct the airflow into the exhaust chamber. A grill 16 is connected to the bottom panel 14 to prevent accidental contact with the fan when in operation. Grease within the grease tray 42 having sufficient liquidity drains towards a drain hole at the bottom rear of the grease tray and travels through conduit 43 to external grease receptacle 20 for disposal.

The exhaust chamber housing 46 is connected to the top panel 44 of the range hood, preferably by welding flange 48 to top panel 44. While the welded junction between the exhaust housing 46 and top panel 44 is sufficient from the standpoint of structural connectivity, achieving a suitable seal between the flange 48 and the top panel 44 is difficult. The lack of a sufficient seal results in poor ventilation—with gases to be vented from the exhaust chamber 45 instead passing through the junction between flange 48 and top panel 44 into the range hood interior 41. This reduces the efficiency of the range hood. In addition, accumulated grease within interior 41 is hard to get at in order to clean the interior. This connection is especially ineffective in those range hoods having cleaning systems where cleaning fluid is injected into the exhaust chamber in order to flush out any accumulated grease. The pressure of the fluid itself and the added force from the spinning fan cause fluid and grease to pass through any openings between the flange 48 and the top panel 44 leaking out into the range hood interior 41 contaminating it.

Different designs have been developed in order to overcome the problems associated with an ineffective connection between the exhaust chamber housing and the top panel of the range hood body. One such design is a range hood having a fully enclosed exhaust chamber housing having top, bottom and side surfaces. An example of this type of range hood is disclosed in U.S. Pat. No. 6,732,729. The motor housing of the '729 patent is formed of two halves, a top half and a bottom half. The two halves are joined together in such a fashion that no liquid can pass between the connection. While the range hood of the '729 patent overcomes the problem of undesirable leakage of fluid out of the exhaust chamber, it is more costly to make as it requires increased materials as compared to the exhaust chamber of the prior art range hood shown in FIG. 1 and takes more time to assemble.

A further design is taught in U.S. Pat. No. 6,719,622. In the '722 patent, the range hood (or smoke exhaust structure as it is described therein) has an exhaust chamber formed of two part construction, comprising a first face connected to the hood body and a wind chamber releasably connectable to the first face. The wind chamber has a peripheral wall and a second face (a bottom) opposite the first face. The top edge of the peripheral wall fits into a channel in the first face and the wind chamber is latched to the first face. Once again, the problem of undesirable leakage of fluid between the connection between the top panel of the range hood body and the exhaust chamber is overcome by adding a top surface to the exhaust chamber so as to have a fully enclosed exhaust chamber mounted within the range hood enclosure. As above, this design is more costly to make as it requires increased materials as compared to those range hoods having a “topless” exhaust chamber housing connected directly to the top panel of the range hood.

Accordingly, there is an ongoing need for a range hood having an improved connection between the motor housing and the range hood while minimizing the amount of material used.

This and other objects of the invention will be better understood by reference to the detailed description of the preferred embodiment which follows.

SUMMARY OF THE INVENTION

According to the present invention there is provided a kitchen range hood comprising a hood body having a top panel and defining an enclosure and having an exhaust chamber housing mounted within the hood body. The exhaust chamber housing has a peripheral wall terminating in a flange at one end and a bottom surface having at least one intake opening at the opposite end. The flange is connected to the top panel. A pocket is formed between the flange and the top panel, the pocket being filled with a seal.

In another aspect, the top panel has a raised portion within which the flange is seated.

In another aspect, the flange has a stepped portion defining the pocket. The stepped portion can be located at the outer end of the flange or proximal to the peripheral wall.

In another aspect, the flange has a recessed mid-portion defining the pocket.

In another aspect, the top panel has a raised portion defining the pocket.

The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT

A detailed description of the preferred embodiment will be provided by reference to the drawings thereof and of the prior art, in which:

FIG. 1 is a partial cross-sectional view of a kitchen range hood as known in the prior art;

FIG. 2 is a partial cross-sectional view of a kitchen range hood according to a preferred embodiment of the invention;

FIG. 3 is a cross-sectional view of the connection between the exhaust chamber housing and range hood body shown in FIG. 2 marked as 3-3;

FIG. 3A is an exploded cross-sectional view of the connection shown in FIG. 3;

FIG. 3B is a cross-sectional view of the connection shown in FIG. 3 also showing the insertion of sealant;

FIG. 4 is a cross-sectional view of an alternative embodiment of the connection between the exhaust chamber housing and range hood body;

FIG. 5 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 6 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 7 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 8 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 9 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 10 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 11 is a cross-sectional view of a further alternative embodiment of the connection;

FIG. 12 is a cross-sectional view of a further alternative embodiment of the connection; and

FIG. 13 is a cross-sectional view of a further alternative embodiment of the connection.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of a range hood 2 according to the invention is shown in FIG. 2. Range hood 2 has a range hood body having a top panel 4, a bottom panel 14 and a front, rear and sides forming an enclosure within which an exhaust chamber housing 6 is mounted. The connection between the exhaust chamber housing 6 and the top panel 4 will be described in greater detail below.

The exhaust chamber housing 6 and top panel 4 define an exhaust chamber 30 within which at least one motor 8 and fan 10 are mounted. The exhaust chamber housing has a perimeter side wall 7 terminating in an outwardly extending flange 5 at the top and terminating in a bottom surface 9 having at least one air intake opening defined therein. The intake opening in the exhaust chamber housing is aligned with the air intake defined in the bottom panel 14 of the range hood. A grease tray 12 is releasably connectable to the bottom surface 9 to capture any grease that may drip from the fan 10 after the motor 8 has been shut off and to improve air flow into the exhaust chamber through fan 8. A grill 16 is connected to the bottom panel 14 to prevent accidental contact with the fan when in operation. Grease within the exhaust chamber housing interior having sufficient liquidity drains towards a drain hole (not shown) at the bottom rear of the exhaust chamber housing and travels through conduit 18 to external grease receptacle 20 for disposal.

Referring now to FIG. 3, the connection between the exhaust chamber housing 6 and the top panel 4 will now be described in greater detail. Top panel 4 has a raised portion 22, preferably from pressing and/or machining, forming a recess 21 on the inner surface of top panel 4 as shown in FIG. 3A. Raised portion 22 is sized and shaped to correspond to flange 5 of the exhaust chamber housing 6. Flange 5 of the exhaust chamber housing 6 is dimensioned to fit within the recess 21 formed by raised portion 22. Flange 5 extends substantially perpendicular to wall 7 and has a downwardly stepped end-portion 26 forming a step 25. When flange 5 is seated in recess 21, a pocket 70 is formed between downwardly stepped end-portion 26 and top panel 4.

An o-ring 28 (suitably sized and dimensioned and adapted to be fitted in a potentially non-circular pocket, the exhaust chamber typically having a FIG. 8 shape when viewed from above) or other suitable seal is placed in step 25 and is compressed in pocket 70 when flange 5 is seated in the recess 21 so as to form a tight seal. Preferably, a gap 32 is present between the outer edge 36 of the flange 5 and the bottom outer edge 34 of the raised portion 22 of top panel 4 providing an opening to the pocket 70. The gap is sized so as to be sufficiently small that the o-ring cannot fit through, but so that sealant can be injected through the gap in addition to, or as an alternative to, the o-ring. FIG. 3B shows silicone sealant 27 being injected through gap 32 into the pocket 70 formed by step 25 between stepped end-portion 26 and raised portion 22. The silicone sealant 27 is injected through gap 32 via a tube of sealant 29.

Flange 5 is connected to top panel 4, preferably by welding. The welding of the connection according to the invention is preferably performed by a form of spot welding as is known in the art. A broad, flat electrode is used for the top of the connection, namely the raised portion 22 of the top panel 4 that overlies flange 5, while a point electrode is used on the bottom (hidden) surface of the connection. The use of a broad flat electrode on the top surface acts to distribute the current across the surface of the connection, while the point electrode concentrates the current. Preferably any silicone or other sealant to be used is injected after welding of the exhaust chamber housing 6 to the top panel 4.

By machining the top panel 4 to form raised portion 22, the structural rigidity of the top panel is increased. In addition, because raised portion 22 defines the recess 21 within which flange 5 is seated, it provides an easy reference for the initial placement of the exhaust chamber housing against top surface 4 during the manufacturing process. The seal provided by the o-ring 28 and/or sealant prevents the escape of any grease-laden gases, or cleaning fluid should it be injected into the exhaust chamber. Because the gap 32 is located on the exterior of the exhaust chamber housing 6, it provides easier access for the insertion of sealant.

Alternative connections between the exhaust chamber housing and the top panel of the range hood are shown in FIGS. 4-13. Identical reference numbers have been used to refer to those portions of the alternative embodiments identical to the preferred embodiment described above. In particular, reference numeral 70 has been used in each figure to refer to the pocket formed between the exhaust chamber housing and the top panel.

In the alternative embodiment shown in FIG. 4, exhaust housing 106 terminates in a flange 110 having a stepped portion 108. The stepped portion 108 forms the pocket 70 within which the seal is seated when flange 110 is connected to raised portion 22 of top panel 4. The seal may take the form of an o-ring 28, silicone sealant, or another suitable sealing material. Preferably, a gap 112 is present between top inner edge 109 of the exhaust housing 106 and the bottom inner edge 23 of the raised portion 22 of top panel 4 providing an opening to pocket 70. The gap is sized so as to be sufficiently small that the o-ring cannot fit through, but so that sealant can be injected through the gap in addition to, or as an alternative to, the o-ring. While providing a suitable seal for preventing the leakage of grease-laden gases and fluids, placement of the gap 112 in the interior of the exhaust chamber housing 106 makes it more difficult to access for the insertion of sealant, should that be desired.

In the alternative embodiment shown in FIG. 5, flange 205 of exhaust chamber housing 206 extends substantially perpendicular to wall 207, has a recessed mid-portion 226 forming a channel 229, and terminates in a substantially horizontal end 224. An o-ring 28 or other suitable seal is placed in the pocket 70 formed by channel 229 of recessed mid-portion 226 and top panel 4. The o-ring 28 is compressed in pocket 70 when flange 205 is seated in the recess 21 formed by raised portion 22 thereby forming a tight seal. Flange 205 is connected to top panel 4, preferably by welding on either or both sides of recessed mid-portion 226.

In the alternative embodiment shown in FIG. 6, top panel 44 is substantially horizontal in the area of the connection with the exhaust chamber housing 206. Exhaust housing 206 has a flange 205 having recessed mid-portion 226 and substantially horizontal end portion 224. O-ring 28 (or other suitable sealing material) is seated in the pocket 70 formed by recessed mid-portion 226 and top panel 44. The o-ring 28 is compressed to form a seal when flange 205 is connected to top panel 44.

In the alternative embodiment shown in FIG. 7, top panel 54 has a raised portion 56 forming a pocket 70 within which an o-ring 28 may be seated. The flange 48 of the exhaust housing 46 is connected to top panel 54 so as to seal o-ring 28 within the pocket 70 between flange 48 and the raised portion 56 of top panel 54. Preferably, flange 48 is connected to top panel 54 by welding on either or both sides of raised portion 56.

In the alternative embodiment shown in FIG. 8, top panel 154 has a raised portion 156. Exhaust chamber housing 146 has a flange 148. When flange 148 is connected to top panel 154, a pocket 70 is formed within which an o-ring 28 or other suitable seal may be seated. Flange 148 and raised portion 156 are sized and dimensioned such that a gap 142 is present as between the outer end 149 of flange 148 and the bottom outer edge 134 of the raised portion 156 of top panel 154 providing an opening to pocket 70. The gap 142 is sized so as to be sufficiently small that the o-ring cannot fit through, but so that sealant can be injected through the gap in addition to, or as an alternative to, the o-ring.

In the alternative embodiment shown in FIG. 9, top panel 44 is substantially horizontal in the area of the connection with the exhaust chamber housing 6. The downwardly stepped end-portion 26 of flange 5 forms a pocket 70 when flange 5 is connected to top panel 44. An o-ring, silicone sealant or other suitable seal may be positioned in pocket 70 so as to form a seal between exhaust housing 6 and top panel 44.

In the alternative embodiment shown in FIG. 10, top panel 44 is substantially horizontal in the area of the connection with the exhaust chamber housing 106. Exhaust housing 106 terminates in flange 110 having stepped portion 108. The stepped portion 108 forms the pocket 70 within which the seal is seated when flange 110 is connected to top panel 44. Preferably, the seal will take the form of a silicone sealant or other suitable sealant material injected into the pocket 70.

In the alternative embodiment shown in FIG. 11, top panel 154 has raised portion 156, which, in conjunction with flange 148 of exhaust chamber housing 146 defines pocket 70, within which an o-ring 28 or other suitable seal may be seated. In this embodiment, flange 148 and raised portion 156 are sized and dimensioned such that a gap 242 is present as between the inner edge 144 of flange 148 and the bottom inner edge 140 of the raised portion 156 of top panel 154, the gap 242 providing an opening to pocket 70. The gap 242 is sized so as to be sufficiently small that an o-ring cannot fit through, but so that sealant can be injected through the gap 242 in addition to, or as an alternative to, the o-ring.

In the alternative embodiment shown in FIG. 12, top panel 60 has a first raised portion 62, a recessed portion 64 in the shape of a “V” and a second raised portion 74. Exhaust housing 66 has a flange 69 having a first portion 68, a recessed portion 70 in the shape of a “V” and a second portion 72. Flange 69 is sized and dimensioned to correspond to the contour defined by the first and second raised portions 62, 74 and the recessed portion 64. Preferably, flange 69 is welded to top panel 60 on either side of the recessed “V” portion. Top panel 60 and flange 69 can be shaped either before or after they are welded together by pressing the metal panels. The sharply pressed “V” portion acts as a barrier to grease laden gases, preventing grease (and other liquids, such as cleaning fluid) from getting into the range hood interior.

In the alternative embodiment shown in FIG. 13, an additional “V” has been pressed into the top panel 80 of the range hood body and the exhaust chamber housing 90. Top panel 80 has a raised portion 88 having two recessed portions 82 and 86, each recessed portion being substantially “V” shaped. Preferably the “V”-shaped recesses are adjacent to one another, meeting at peak 84. Exhaust chamber housing 90 has a flange 99 shaped to correspond to the raised portion 88 of the top panel. Flange 99 has a first “V”-shaped recess 92 corresponding to recess 82, and a second “V”-shaped recess 96 corresponding to recess 86, with peak 94 corresponding to peak 84. Welding of the flange 99 to the top panel 80 is preferably completed with the horizontal portion of the flange referred to with reference numeral 98. Top panel 80 and flange 99 can be shaped either before or after they are welded together by pressing of the metal panels. The sharply pressed “V” portions act as a barrier to grease laden gases, preventing grease (and other liquids, such as cleaning fluid) from getting into the range hood interior.

The embodiments of the invention provide a seal as between the top panel of the range hood body and the exhaust chamber housing, thereby preventing the escape of grease-laden gases and fluids. Because the top panel forms the top of the exhaust chamber, the materials used are minimized.

The above description has been intended to illustrate the preferred and alternative embodiments of the invention. It will be appreciated that modifications and adaptations to such embodiments may be practiced without departing from the scope of the invention, such scope being most properly defined by reference to this specification as a whole and to the following claims. 

1. A kitchen range hood comprising: a hood body having a top panel and defining an enclosure; an exhaust chamber housing mounted within said hood body, said housing having a peripheral wall terminating in a flange at one end and a bottom surface at the opposite end, said bottom surface having at least one intake opening; said flange being connected to said top panel; and a pocket between said flange and said top panel, said pocket being filled with a seal.
 2. The kitchen range hood according to claim 1 wherein said flange is secured to said top panel by welding.
 3. The kitchen range hood of according to claim 1 wherein said top panel having a raised portion.
 4. The kitchen range hood of claim 3 wherein said flange is fitted within said raised portion of said top panel.
 5. The kitchen range hood of claim 4 wherein said flange having a stepped portion defining said pocket.
 6. The kitchen range hood of claim 5 wherein said seal comprises an o-ring seated in said pocket between said stepped portion and said top panel.
 7. The kitchen range hood of claim 5 wherein said seal comprises a sealant injected into said pocket between said stepped portion and said top panel.
 8. The kitchen range hood of claim 6 wherein said seal further comprises a sealant injected into said pocket between said stepped portion and said top panel.
 9. The kitchen range hood of claim 4 further comprising a gap between said flange and said top panel opening into said pocket.
 10. The kitchen range hood of claim 9 wherein said seal comprises a sealant injected into said pocket through said gap.
 11. The kitchen range hood of claim 5 wherein said stepped portion of said flange is a downwardly stepped outer end defining said pocket between said flange and said top panel.
 12. The kitchen range hood of claim 5 wherein said stepped portion of said flange is proximal to said peripheral wall.
 13. The kitchen range hood of claim 4 wherein said flange having a recessed middle portion defining said pocket.
 14. The kitchen range hood of claim 13 wherein said seal comprises an o-ring seated in said pocket formed by said recessed middle portion.
 15. The kitchen range hood of claim 1 wherein said flange having a stepped portion defining said pocket.
 16. The kitchen range hood of claim 15 wherein said seal comprises an o-ring seated in said pocket between said stepped portion and said top panel.
 17. The kitchen range hood of claim 16 wherein said seal comprises a sealant injected into said pocket between said stepped portion and said top panel.
 18. The kitchen range hood of claim 15 wherein said stepped portion of said flange is a downwardly stepped outer end defining said pocket between said flange and said top panel.
 19. The kitchen range hood of claim 15 wherein said stepped portion of said flange is proximal to said peripheral wall.
 20. The kitchen range hood of claim 1 wherein said flange having a recessed middle portion defining said pocket.
 21. The kitchen range hood of claim 20 wherein said seal comprises an o-ring seated in said pocked formed by said recessed middle portion.
 22. The kitchen range hood of claim 3 wherein said raised portion of said top panel defines said pocket between said top panel and said flange.
 23. The kitchen range hood of claim 22 wherein said seal comprises an o-ring.
 24. The kitchen range hood of claim 22 further comprising a gap between said top panel and said flange providing an opening to said pocket. 